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Just as a side note, Tohatsu is the manufacturer of all small outboards. They build them and badge them as Suzuki, Mercury, Evinrude etc. Kepp your fuel clean and run them periodically. I dont drain the bowl or let it run dry and I also use alcohol free fuel with stabilizer.

At the risk of jinxing myself, I thought I would post this update so that it might help someone in the future.

We thought that after cleaning the carb and changing the spark plug our troubles were fixed because the outboard idled smoothly on the mooring. Unfortunately when we actually put it in gear and headed out we discovered that while the symptoms had improved somewhat, the engine still wasn't happy.

Someone on this forum had suggested it was likely either the carb or the fuel lines, so we replaced the lines running from the external fuel tank to the outboard (including the lines leading to and from the separator filter), and this included a new primer bulb. I'm thinking perhaps the PO had used the lines from the previous, smaller outboard because the new ones seemed more robust and "bigger". Regardless, they likely needed to be replaced because when Mr. Cthoops started to remove the old line from the separator filter, it immediately split in half.

Anyway, I don't know if the lines weren't large enough or there was gunk that had built up in them, but the bottom line is we've taken the boat out twice since replacing all of this and the outboard has truly never sounded better. It's quieter and runs ever-so-smooth. I am SO relieved!

Thanks again for the advice, everyone.

It was likely the old gas that was still in the fuel line.

Regards,
Brad

08-08-2013 07:55 PM

Fau

Re: Tohatsu troubles

It is almost always the fuel.

08-08-2013 07:33 PM

templar

Re: Tohatsu troubles

If you suspect the fuel is the problem here is a quick easy way to check it. It will take about 15 minutes to do so.
First disconnect the fuel line from the carb and drain some fuel into a container, I prefer to use a glass jar, about a 1/2 to a cup is all that you need to drain. Then set that aside and let it set without being agitated. After the fuel has set then look at the bottom of the jar from the top. If there is water in the fuel you will be able to see it.
If there is not water in the fuel, tip the tank so you can look in the fuel fill cap and let it set for a bit and see if there is water in it, water will always go to the lowest point so make sure you are looking in the corner and it is the lowest point, prop the tank up if you need to.
when you have ruled out the water in the fuel, the next step is to clean the jet at the bottom of the fuel bowl. First drain the bowl and then remove it, at the bottom of the lowest part of the pickup is a brass piece, use a flat tipped screwdriver to remove it and check to see if it is clear. I will generally run a small wire through it just to be sure and shoot some carb clearer through it. Even a small piece of debris or dirt will make the engine run rough or not even start.
I use a 3.5 tohatsu engine on my dinghy and have had the same problems as described and this is what I have found the problem to be.
Also I use just regular fuel from the gas station the 87 octane type that has ethanol in it. I have found that it works fine but it does take a toll on the fuel line after about a year so I replace it. I do not put any additives in the fuel, the trick is to use the fuel with in a 6 month or less period.
Hopefully this will help in solving your problem, fair winds and the best of sailing to you.

08-08-2013 03:57 PM

dabnis

Re: Tohatsu troubles

In my snowblower, generator, and various outboards, running it dry still leaves a small amount of fuel in the bowl. Draining gets virtually all of it out. I forgot to drain one season and paid the price the following spring. Spent several hours fixing it, 2 HP Honda, had to take the tank off to get the carb off.

Paul T

08-08-2013 03:06 PM

MarkSF

Re: Tohatsu troubles

That's not quite accurate. Tohatsu make many small outboards, but not all. They make the small Mercurys, Nissans, and of course Tohatsus, but they don't make Honda, Yamaha, and Suzuki. Not sure about Evinrude.

Letting it run dry or draining the bowl is the single most important thing you can do to keep an outboard running nicely.

08-08-2013 02:53 PM

sebez

Re: Tohatsu troubles

Just as a side note, Tohatsu is the manufacturer of all small outboards. They build them and badge them as Suzuki, Mercury, Evinrude etc. Kepp your fuel clean and run them periodically. I dont drain the bowl or let it run dry and I also use alcohol free fuel with stabilizer.

Interesting link, apparently they will vent outwards at about 7 lbs, which seems like a lot? As mentioned in an earlier post, I modified my cap to vent both ways, which was a mistake as it appears the primer bulb doesn't work well without pressure in the tank?

If you don't want to be sprayed with gas when disconnecting the hose, just loosen the cap first. I just ordered a replacement cap for the cap I modified, about a $50 mistake.

Wow, thanks Paul T, it never occurred to me that the valve was one way. My dink and motor have been sitting in the sun all week. I just sent my wife down to the boat to check the gas tank, damn. I should have thought about that.

The new epa-compliant tanks will hold pressure up to something between 5 and 7 PSI. They will swell visibly, but have been tested to hold this pressure. T

The pressure your wife saw might have seemed a lot, but may have been within the designed range. Still, it's not good practice to let the tank sit in the sun.

A vital part of the safety of these tanks is not over-filling them - they need some air space at the top of the tank.